Method of making a distensible dilatation balloon using a block copolymer

ABSTRACT

Balloons and balloon catheters with a superior overall combination of distensibility, elastic stress response and strength. The improved properties of the balloons result from the method or process used to form the balloons, as well as the polymeric materials used in said balloon forming process. Additionally, the enhanced combination of properties of the balloons will not be adversely affected by the novel sterilization process contemplated by this invention. A process for forming a balloon involves providing a parison of a block copolymer, subjecting the parison to at least one axial stretch step and at least one radial expansion step, and heating the expanded parison to a temperature below the melting temperature of the block copolymer.

BACKGROUND OF INVENTION

Surgical procedures employing balloons and medical devices incorporatingthose balloons (i.e., balloon catheters) are becoming more common androutine. These procedures, such as angioplasty procedures, are conductedwhen it becomes necessary to expand or open narrow or obstructedopenings in blood vessels and other passageways in the body to increasethe flow through the obstructed areas. For example, in an angioplastyprocedure, a dilatation balloon catheter is used to enlarge or open anoccluded blood vessel which is partially restricted or obstructed due tothe existence of a hardened stenosis or buildup within the vessel. Thisprocedure requires that a balloon catheter be inserted into thepatient's body and positioned within the vessel so that the balloon,when inflated, will dilate the site of the obstruction or stenosis sothat the obstruction or stenosis is minimized, thereby resulting inincreased blood flow through the vessel. Often, however, a stenosisrequires treatment with multiple balloon inflations. Additionally, manytimes there are multiple stenoses within the same vessel or artery. Suchconditions require that either the same dilatation balloon must besubjected to repeated inflations, or that multiple dilatation balloonsmust be used to treat an individual stenosis or the multiple stenoseswithin the same vessel or artery. Additionally, balloons and medicaldevices incorporating those balloons may also be used to administerdrugs to a patient.

Traditionally, the balloons available to physicians were classified aseither "compliant" or "noncompliant". This classification is based uponthe operating characteristics of the individual balloon, which in turndepended upon the process used in forming the balloon, as well as thematerial used in the balloon forming process. Both types of balloonsprovide advantageous qualities which were not available from the other.

A balloon which is classified as "noncompliant" is characterized by theballoon's inability to grow or expand appreciably beyond its rated ornominal diameter. "Noncompliant" balloons are referred to as havingminimal distensibility. In balloons currently known in the art (e.g.,polyethylene terephthalate), this minimal distensibility results fromthe strength and rigidity of the molecular chains which make up the basepolymer, as well as the orientation and structure of those chainsresulting from the balloon formation process. The strength resultingfrom this highly oriented structure is so great that when the balloon issubjected typical inflation or operating pressures (i.e., about 70 psito over 200 psi), it will not be stressed above the yield point of thepolymeric material.

The yield point of a material is defined as the stress at which theindividual molecular chains move in relation to one another such thatwhen the pressure or stress is relieved, there is permanent deformationof the structure. When a material is subjected to pressure or stressbelow its yield point, the material will consistently follow the samestress-strain curve when subjected to multiple cycles of applying andrelieving the stress or pressure. A material which exhibits the abilityto follow the same stress-strain curve during the repeated applicationand relief of stress is defined as being elastic and as having a highdegree of elastic stress response. This elastic behavior is highlydesirable in balloons in order to ensure consistent and predictableballoon sizing regardless of the balloon's previous inflation history.

A balloon which is referred to as being "compliant" is characterized bythe balloon's ability to grow or expand beyond its nominal or rateddiameter. In balloons currently known in the art (e.g., polyethylene,polyvinylchloride), the balloon's "compliant" nature or distensibilityresults from the chemical structure of the polymeric material used inthe formation of the balloon, as well as the balloon forming process.These polymeric materials have a relatively low yield point. Thus, theinflation pressures used in dilation procedures are typically above theyield point of the materials used to form distensible balloons. Adistensible or "compliant" balloon when inflated to normal operatingpressures, which are greater than the polymeric material's yield point,is subjected to stress sufficient to permanently realign the individualmolecular chains of the polymeric material. The realignment ofindividual polymer chains permits the balloon to expand beyond itsnominal or rated diameter. However, since this realignment is permanent,the balloon will not follow its original stress-strain curve onsubsequent inflation-deflation cycles. Therefore, the balloon balloonupon subsequent inflations, will achieve diameters which are greaterthan the diameters which were originally obtained at any given pressureduring the course of the balloon's initial inflation.

The term "elastic", as it is used in connection with this invention,refers only to the ability of a material to follow the samestress-strain curve upon the multiple applications of stress. See Beer,F. et al., Mechanics of Materials (McGraw-Hill Book Company 1981), pp.39-40. Elasticity, however, is not necessarily a function of howdistensible a material is. It is possible to have an elastic,non-distensible material or a non-elastic, distensible material. This isbest illustrated in FIGS. 1, 2 and 3.

FIG. 1 represents an elastic, essentially non-distensible material. Ifthis material was used to form a balloon, the balloon would beconsidered non-distensible because there is very little change in strain(diameter) as the stress applied is increased (inflation pressure). Theballoon would be elastic because it follows essentially the samestress-strain (pressure-diameter) curve with the second application ofstress (inflation).

FIG. 2 represents an elastic, distensible material. If this material wasused to form a balloon, the balloon would be considered distensiblebecause there is significant change in strain (diameter) as the stressapplied is increased (inflation pressure). The balloon would beconsidered elastic because it follows essentially the same stress-strain(pressure-diameter) curve with the second application of stress(inflation).

FIG. 3 represents an inelastic, distensible material. Like FIG. 2, FIG.3 shows a significant change in strain (diameter) and would therefore beconsidered a distensible balloon material. Unlike FIGS. 1 and 2,however, the same stress-strain (pressure-diameter) curve is notmaintained upon the second application of stress (inflation).

It has been found that the optimal size of a dilatation balloon is about0.9 to about 1.3 the size of the vessel being treated. See Nichols etat., Importance of Balloon Size in Coronary Angioplasty, J. AmericanCollege of Cardiology, Vol. 13, 1094 (1989). If an undersized balloon isused, there is a high incidence of significant residual stenosis and agreater need for subsequent dilatation procedures. However, if anoversized balloon is used, there is an increased chance of coronarydissection. Therefore, physicians desire to use a balloon which willclosely approximate the size of the occluded vessel or obstructed cavitybeing treated.

Because physiological vessels such as arteries are generally tapered,the nominal or rated diameter of balloons commercially available oftendo not correspond to the size of the vessel being treated. Physicians,therefore, are often faced with the prospect of using an undersized"compliant" balloon which can be expanded beyond its nominal or rateddiameter, or an oversized "noncompliant" balloon which will follow thesame stress-strain curve during multiple inflations (i.e., is elastic).Thus, physicians can choose from two general types of balloons dependingupon whether they require a balloon which grows beyond nominal diameter.They may choose a "noncompliant" balloon if they require a relativelyhigh strength balloon which will not expand much beyond its nominal orrated diameter, or a "compliant" balloon if they require a balloon whichis capable of expanding considerably beyond the normal or rateddiameter. As will be shown below, each of these properties isadvantageous. However, it would be desirable to have to have a"compliant" or distensible balloon which also has the elastic stressresponse of a "noncompliant" balloon, as well as sufficient strength tobe used in dilatation procedures.

Because physicians using a dilatation balloon do not know prior to theprocedure what inflation pressures will be required to dilate a givenobstruction or stenosis, it is desirable that the balloon being usedhave strength capable of withstanding the high inflation pressurestypically associated with these procedures (i.e., about 70 to over 200psi). A high strength dilatation balloon, which is capable ofwithstanding increased inflation pressure, is safer to use since thechances of the balloon bursting during the procedure are minimized.

Strength of a balloon is typically quantified by calculating theballoon's wall tensile strength. The overall strength of a balloon canbe increased by increasing the balloon's wall thickness. As the wallthickness is increased, the balloon is capable of withstanding higherinflation pressures. However, as the wall thickness of the balloon isincreased, the folded profile of the balloon, as well as the balloon'sflexibility, may be adversely affected.

The relationship between the ultimate strength of the balloon, theinflation pressure which the balloon can withstand and the balloon'swall thickness is determined by the well known membrane equation:##EQU1##

Depending upon the material used to form the balloon, the nominal, orrated diameter is achieved typically when the balloon is inflatedbetween to about 5 bars to about 8 bars. The burst pressure isdetermined at 37° C.

Since balloons, particularly dilatation balloons, must have the abilityto traverse the confines of the obstructed areas to be treated, it isdesirable to have a balloon which has a narrow folded profile. This"profile" represents the smallest opening through which the balloon, inits deflated state, may pass. The profile of the balloon depends inlarge part upon the wall thickness of the finished balloon (i.e., thesterilized dilatation balloon product). Therefore, it is desirable for afinished balloon product to have a folded profile which is as narrow aspossible, particularly if the balloon is to be used in an angioplastyprocedure.

Another important characteristic of balloons in general, and morespecifically dilatation balloons, is the distensibility of the finishedballoon product. Distensibility, also referred to as percent of radialexpansion, is typically determined by comparing the nominal or rateddiameter of the balloon with the diameter at some arbitrarily selectedhigher pressure (e.g., 10 bars). The distensibility or percent radialexpansion is calculated using the following formula with allmeasurements taking place at about 37° C.: ##EQU2## For example,balloons made of polyethylene terephthalate have a low distensibility(i.e., less than about 5% at 200 psi). See for example U.S. Pat. Nos.32,983 and 33,561 to Levy which discloses balloons formed frompolyethylene terephthalate and other polymeric materials.

It is also desirable that the balloon be elastic or have a high degreeof elastic stress response. Elasticity, which also can be referred to asthe repeatability of a balloon, is characterized by the ability of theballoon to consistently follow the same stress-strain curve after beingsubjected to multiple inflations to normal operating or inflationpressures (i.e., about 10 bars or greater). That is, a balloon which hasa high degree of elastic stress response will retain the samediameter-pressure relationship and will consistently obtain the samediameter at the same pressure during repeated inflation-deflationcycles. Balloons which have poor elasticity or a low degree of elasticstress response have a tendency to "creep" or "deform" after multipleinflations and fail to return to their nominal or rated diameters afterbeing subjected to multiple inflations at increased pressures.

A dilatation balloon which has a high degree of elastic stress responseis particularly desirable when a physician is treating multiple stenoseswithin the same artery. If the balloon is "inelastic", after the firststenosis is dilated at an increased pressure, the physician would notknow what the balloon's "new" starting diameter is prior to attemptingto dilate subsequent stenoses. If the physician fails to correctly guessthe balloon's "new" diameter prior to beginning treatment of anotherstenosis there is an increased risk of oversizing the balloon whichcould result in coronary artery dissection or other damage to thevessel. Therefore, to ensure the patient's safety, some physicians electto remove the balloon catheter from the patient and reintroduce a newsterile balloon catheter prior to attempting to dilate subsequentstenosis within the same vessel. However, this is time-consuming andundesirable for the patient. Additionally, the cost of the individualballoon catheters prohibits the use of multiple balloon catheters whentreating multiple stenoses within the same vessel. Thus, to minimize thechance of oversizing the balloon when treating multiple stenoses withinthe same vessel, a physician may attempt to use a dilatation balloonwhich is noncompliant. However, as discussed previously, because such aballoon will permit little expansion beyond the balloon's rated ornominal diameter, the physician may not have available a balloon ofsufficient size to safely treat the other stenoses within the samevessel.

Elastic stress response is determined by inflating a balloon to 5 barsat about 37° C. and measuring the balloon's diameter. The balloon isthen inflated to a pressure of 10 bars in about 20 seconds and held foran additional 20 seconds at 37° C. The balloon's diameter is thenmeasured. The internal pressure of the balloon is then decreased to 5bars and the "new" 5 bar diameter of the balloons is determined. Forthis invention, the elastic stress response or repeatability iscalculated using the following equation: ##EQU3##

A balloon with maximum or complete elastic stress response permits theballoon, after being inflated to a pressure of 10 bars, to return to thesame diameter it had at 5 bars prior to the inflation to the higherpressure. Such a balloon would have maximum repeatability, or an elasticstress response of 0.00. As the repeatability of the balloon decreases,the elastic stress response decreases and, as defined above, numericallybecomes greater than 0.00. For example, balloons formed from polyolefincopolymers in the art have poor repeatability and a relatively lowdegree of elastic stress response and have a numerical elastic stressresponse of about 9.

It would be particularly desirable if a "compliant" balloon was able topossess an adequate degree of distensibility so that the balloon couldbe inflated to correspond to the size of the vessel being treated, whileat the same time being highly elastic to ensure repeatable sizing and ahigh degree of elastic stress response so that the physician would knowthe balloon's "new" diameter at all inflation pressures prior toattempting to dilate multiple stenoses within the same vessel. Thisenhanced combination of properties would allow physicians to conductdilation procedures in a safer manner in arteries where the physicianrequires balloon sizing not conveniently provided by "noncompliant"balloon products currently available in the art.

Another desirable characteristic of a balloon is flexibility. Improvedflexibility will permit a balloon to traverse, not only occludedarteries, but also other obstructed or narrow body cavities and openingsresulting in minimal damage to the vessel or cavity through which theballoon catheter is being navigated.

A further desirable property of a dilatation balloon, is the opticalclarity of the finished balloon product. Although the optical claritywill not adversely affect a balloon's overall ability to dilate astenosis or obstruction, most physicians will not use a balloon whichhas a cloudy appearance. The optical characteristics of a balloon orballoon catheter, therefore, must be taken into account when forming aballoon.

While the foregoing properties are desirable in balloons, theseattributes are typically adversely affected by the sterilization processwhich all balloons and balloon catheters must be subjected to prior totheir use in the human body. For example, when a balloon in the art isexposed to the increased temperature and humidity of a traditionalsterilization process (e.g., high humidity, temperature of about 50°-60°C., about 12% ethylene oxide and about 88% Freon™ for approximately12-16 hours) the balloon tends to shrink which causes a correspondingincrease in wall thickness. Moreover, this increase in wall thicknesswill adversely affect the folded profile of the sterilized balloonproduct. Furthermore, the distensibility of many balloons is adverselyaffected by the sterilization processes currently used in the art.Therefore, it is also desirable that the sterilization process used totreat balloons and balloon catheters provide adequate sterilizationwhile at the same time not adversely affecting the physicalcharacteristics of the finished balloon or balloon catheter product.

It has now been found that novel distensible balloons, particularlydilatation balloons, can be formed by processing a polymeric materialcomposed of polymer chains having sufficient regions of molecularstructure with inter-molecular chain interaction to ensure the integrityand strength of the structure, as well as sufficient regions whichpermit sections of the polymer chains to "uncoil" to permit growth. Theballoons contemplated by this invention (i) are sufficiently distensible(i.e., about 5 to about 20%) to allow treatment of various sizedarteries, (ii) have a high degree of elastic stress response (i.e., lessthan about 5.00) which permits the physician to treat multiple stenoseswithin the same artery without having to be concerned with increasingballoon diameter after repeated inflations and (iii) have strengthsufficient to treat hardened stenoses (i.e., greater than about 14,000psi). The balloons formed using the process of this invention will havean overall advantageous combination of these physical properties i.e.,distensibility, elastic stress response and tensile strength, superiorto those exhibited by the "compliant" balloons currently available. Ithas also been found that these enhanced properties will not be adverselyaffected by subjecting the balloons and balloon catheters formedfollowing the method or process of this invention to a novelsterilization process. This novel balloon forming process and novelsterilization process can be used regardless of whether the balloon iscoated.

SUMMARY OF THE INVENTION

It is an object of this invention to provide a method or process forproducing a balloon, preferably a dilatation balloon, which exhibits animproved overall combination of physical properties, such asdistensibility, elastic stress response and strength, superior to thoseexhibited by "compliant" balloons currently known in the art.

It is further the object of this invention to provide a novel balloonand a novel balloon catheter in which the balloon exhibits anadvantageous overall combination of distensibility, elastic stressresponse and strength which combination of properties will not beadversely affected by sterilization.

Still another object of this invention is to provide an improvedsterilization procedure which will not adversely affect thedistensibility, elastic stress response and strength of the balloons andballoons of the balloon catheters of this invention.

It is still a further object of this invention to provide a processwhich will ensure that the balloons formed will have improved opticalclarity.

These objects, as well as others, which will become apparent from thedescription which follows, are achieved by forming these novel balloonsand balloon catheters using the novel process of this invention fromcertain polymeric materials composed of polymer chains having regions ofinter-molecular chain interaction separated by regions in which thoseindividual portions of the polymer chains have the ability to uncoil orstretch. Therefore, the present invention includes (1) novel balloonsand balloon catheters which have an improved overall combination ofdistensibility, elastic stress response and strength, (2) the process ormethod of forming balloons and balloon catheters from polymericmaterials which will result in balloons and balloon catheters exhibitingthese improved properties and (3) a novel sterilization process whichwill not adversely affect these enhanced properties.

The present invention contemplates balloons characterized by an improvedoverall combination of distensibility, elastic stress response and walltensile strength made by the process comprising subjecting a parison,made of a block copolymer having polymer chains with regions ofinter-molecular chain interaction separated by regions in which thoseindividual portions of the polymer chains have the ability to stretch oruncoil to at least one axial stretch and at least one radial expansionstep. The expanded parison is then subjected to a heat set step toprovide the expanded parison and resulting balloon with thermal anddimensional stability. The invention also contemplates a novelsterilization process in which balloons and balloon catheters, afterpreconditioning, are exposed to ethylene oxide at a temperature of about40° C. and a relative humidity of about 50-60% for approximately 6hours. The balloons and balloon catheters are then subjected to anaeration step in which the ethylene oxide is allowed to dissipate. Thenovel sterilization process does not adversely affect the improvedoverall combination of properties exhibited by the balloons of thisinvention.

It should be understood that the foregoing description of the inventionis intended merely to be illustrative and that other embodiments andmodifications may be apparent to those skilled in the art withoutdeparting from the spirit and scope of the invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides for the first time "compliant" balloons,preferably dilatation balloons, which, because of the method or processused to form the balloons, as well as the polymeric materials used inthe balloon forming process, produces balloons having a highly desirablecombination of distensibility, elastic stress response and strength(i.e., distensibility of about 5 to about 20% and preferably in therange of about 6 to about 17%, elastic stress response of not greaterthan about 5.00 and preferably in the range of about 0.75 to about 4.00and wall tensile strength of at least about 14,000 psi, preferably inthe range of about 15,000 to about 40,000 psi and most preferably in therange of about 16,000 to about 30,000 psi). The invention also providesa unique method or process using a heat set step in the formation of theballoons of this invention which ensures that the balloons retain theirdistensibility and strength, and provides balloons with improved opticalclarity. Moreover, the invention provides a novel sterilization processwhich will not adversely affect, to any significant degree, the enhancedcombination of properties which are obtained using the novel balloonforming process of this invention.

The materials which may be used in this novel process or method includepolymeric materials having a molecular structure which are composed ofindividual polymer chains having regions or zones of inter-molecularchain interaction separated by regions or zones in which thoseindividual portions of the polymer chains have the ability to stretch oruncoil. The ability of regions or zones of individual polymer chains touncoil permits the chains to move upon the application of stress.However because these zones are held in place or secured at either endby zones exhibiting inter-molecular chain interaction, the uncoiledportions return to their original position once the applied stress isremoved.

These polymers can be considered to be comprised of polymer chains withindividual regions of crystalline and amorphous material and can bereferred to as "hard" and "soft" segments respectively. The individualpolymer chains are able, to a substantial extent, to coil uponthemselves and/or around each other in such a way that soft segments areassociated with soft segments and hard segments with hard segments,thereby forming separate "domains" approximating soft and hard bodies ofpolymer, each exhibiting its own physical properties in varying degrees.The hard segments are comprised of regions which have significantinter-molecular chain interaction. This provides regions with increasedstrength and increased elastic stress response. In addition to providingstrength, the hard segments are sufficiently rigid to permit the softsegments to stretch and uncoil which provides distensibility.

The ratio of hard to soft segments and individual chemical structure ofthe individual segments define the balloon's distensibility, elasticstress response and strength. Therefore, the polymeric material used inaccordance with this invention should have hard segments present in anamount sufficient to achieve a high degree of elastic stress response(i.e., not greater than about 5.00) and adequate wall tensile strength(i.e., at least about 14,000 psi), while at the same time having anadequate amount of soft segments to ensure that the balloon is alsodistensible (i.e., about 5 to about 20%).

Examples of polymeric materials which have these alternating zones orregions and which may be used in forming the balloons and ballooncatheters of this invention include block copolymers, and physicalmixtures of different polymers. Examples of block copolymers which maybe used include polyester block copolymers, polyamide block copolymersand polyurethane block copolymers. Examples of the mixtures which may beused include mixtures of nylon and polyamide block copolymers andpolyethylene terephthalate and polyester block copolymers. The preferredblock copolymer which can be used in accordance with the process of thisinvention is polyurethane block copolymer. This preferred polymer may bemade, for example, by a reaction between

a) an organic diisocyanate;

b) a polyol; and

c) at least one chain extender.

The preferred polyurethanes which can be used in this invention may bevaried by using different isocyanates and polyols which will result indifferent ratios of hard to soft segments as well as different chemicalinteractions within the individual regions of the polymer.

An example of the most preferred polyurethane is manufactured by The DowChemical Company and marketed under the trade name PELLETHANE 2363-75D.This raw material has a Shore Hardness of about 74 D, a specific gravityof about 1.21, a tensile modulus of about 165,000 psi, a flexuralmodulus of about 190,000 psi, an ultimate tensile strength of about6,980 psi and an ultimate elongation of about 250%.

In accordance with this invention, the balloons are formed from a thinwall parison of a polymeric material, preferably made of a polyurethaneblock copolymer, which is treated in accordance with the process of thisinvention. The novel process contemplated by this invention employs aheat set step which will provide a balloon with temperature anddimensional stability. This stability results from the fact that theballoon is heated above the temperature using in the balloon formingprocess so that the orientation resulting from the processing conditionsis "locked" into position.

The balloons and balloon catheters of this invention may be formed usinga mold which can be provided with a heating element. The mold receives atubular parison made of a polymeric material of the type used inaccordance with the present invention. The ends of the parison extendoutwardly from the mold and one of the ends is sealed while the otherend is affixed to a source of inflation fluid, typically nitrogen gas,under pressure. Clamps or "grippers" are attached to both ends of theparison so that the parison can be drawn apart axially in order toaxially stretch the parison while at the same time said parison iscapable of being expanded radially or "blown" with the inflation fluid.The radial expansion and axial stretch step or steps may be conductedsimultaneously, or depending upon the polymeric material of which theparison is made, following whatever sequence is required to form aballoon. Failure to axial stretch the parison during the balloon formingprocess will result in result in a balloon which will have an unevenwall thickness and which will exhibit a wall tensile strength lower thanthe tensile strength obtained when the parison is both radially expandedand axially stretched.

The polymeric parisons used in this invention are preferably drawnaxially and expanded radially simultaneously within the mold. To improvethe overall properties of the balloons formed, it is desirable that theparison is axially stretched and blown at temperatures above the glasstransition temperature of the polymeric material used. This expansionusually takes place at a temperature between about 80° and about 150° C.depending upon the polymeric material used in the process.

In accordance with this invention, based upon the polymeric materialused, the parison is dimensioned with respect to the intended finalconfiguration of the balloon. It is particularly important that theparison have relatively thin walls. The wall thickness is consideredrelative to the inside diameter of the parison which has wallthickness-to-inside diameter ratios of less than 0.6 and, preferablybetween 0.57 and 0.09 or even lower. The use of a parison with such thinwalls enables the parison to be stretched radially to a greater and moreuniform degree because there is less stress gradient through the wallfrom the surface of the inside diameter to the surface of the outsidediameter. By utilizing a parison which has thin walls, there is lessdifference in the degree to which the inner and outer surfaces of thetubular parison are stretched.

The parison is drawn from a starting length L1 to a drawn length L2which preferably is between about 1.10 to about 6 times the initiallength L1. The tubular parison, which has an initial internal diameterID1 and an outer diameter OD1 is expanded by the inflation fluid emittedunder pressure to the parison to an internal diameter ID2 which ispreferably about 6 to about 8 times the initial internal diameter ID1and an outer diameter OD2 which is about equal to or preferably greaterthan about 3 times the initial outer diameter OD1. The parison ispreferably subjected to between 1 and 5 cycles during which the parisonis axially stretched and radially expanded with an inflation pressure ofbetween about 100 and about 500 psi. Nitrogen gas is the preferableinflation fluid for the radial expansion step.

After the desired number of "blow" cycles have been completed, theexpanded parison is subjected to a heat set or thermoforming step duringwhich the expanded parison, still subjected to an inflation pressure ofabout 100 to about 500 psi, is held at a temperature above thetemperature at which the balloon was axially stretched and radiallyexpanded, but below the melting temperature of the polymeric materialfrom which the parison was formed. This higher temperature inducescrystallization and "freezes" or "locks" the orientation of the polymerchains which resulted from axially stretching and radially expanding theparison. The temperatures which can be used in this heat set step aretherefore dependent upon the particular polymeric material used to formthe parison and the ultimate properties desired in the balloon product(i.e., distensibility, strength and compliancy). The heat set stepensures that the expanded parison and the resulting balloon will havetemperature and dimensional stability. After the heat set step iscompleted, the mold is cooled to about 37° C. The finished balloon willtypically obtain its rated or nominal diameter when inflated to apressure of about 5 to about 8 bars depending upon the polymericmaterial used to form the balloon. The balloon thus formed may beremoved from the mold, and affixed to a catheter.

For example, if the parison is formed from the polyurethane marketed byThe Dow Chemical Company under the trade name PELLETHANE 2363-75D andaxially stretched and radially expanded at a temperature of about90°-100° C., the heat set step would preferably be conducted at about105°-120° C. If this step was conducted at temperatures much above about120° C., the tensile strength of the resulting polyurethane balloonwould decrease significantly. Moreover, if the heat set step wasconducted at temperatures significantly higher than 120° C., thedistensibility of the resulting polyurethane balloon would also beadversely affected. However, if the heat set was conducted attemperatures below about 100° C., the polyurethane balloons formed wouldbe dimensionally unstable resulting in balloons with uneven wallthicknesses. Additionally, the lower heat set temperature would resultin balloons exhibiting physical properties which would more likely beadversely affected during sterilization. Finally, a balloon having acloudy appearance, a property which physicians find particularlyundesirable, would be another consequence of using a low heat settemperature.

It should be noted that some adjustment in the foregoing axial stretchand radial expansion ratios, as well as the expansion and heat settemperatures may be necessary to take into account the difference inphysical properties between the polyurethane block copolymer exemplifiedabove and any other polymeric materials which can be used in accordancewith this invention.

In order to preserve a balloon's distensibility, elastic stressresponse, wall tensile strength and improved optical clarity, theballoon formed must also be subjected to the novel sterilization processcontemplated by the invention. For example, if a sterilization processwhich is currently available in the art is used (e.g., high relativehumidity at about 50°-60° C. in the presence of about 12% ethylene oxideand about 88% Freon™ for about 9-16 hours), the elastic stress response,distensibility and the strength of the balloons contemplated by thisinvention would be adversely affected. When the novel low temperature,low humidity, ethylene oxide sterilization process of this invention isused to sterilize the balloons and balloon catheters of this invention,the elastic stress response, distensibility and strength of the balloonsare not adversely affected to any significant degree.

The novel low temperature, low humidity sterilization process consistsof exposing the balloon or balloon catheter to a preconditioning step attemperature about 35° to about 45° C. and a relative humidity of about55% for about 15 hours. The balloon or balloon catheter is then treatedat a temperature of about 35 to about 45° C. and a relative humidity ofabout 55% with ethylene oxide, preferably in a concentration of about100%. After being exposed to ethylene oxide for about 6 hours, theproducts are aerated and kept at a temperature of about 35 to about 45°C. for about 22 hours, in order to permit the ethylene oxide todissipate. The sterilized balloon products are now ready for human use.

The sterilization process cannot, however, be conducted above the heatset temperature since this would relieve the orientation of the polymerchains which was "locked" into place during heat set process. Thesterilization process appears to be an important factor in determiningthe final physical characteristics of the balloons and balloon cathetersof this invention. Therefore, the novel sterilization process isnecessary to ensure a clinically useful and safe finished balloon andballoon catheter with an overall advantageous combination of physicalproperties (i.e., distensibility, elastic stress response and walltensile strength) superior to those exhibited by the "compliant"balloons of the prior art.

EXAMPLE 1

A parison was made from the polyurethane manufactured by The DowChemical Company and marketed under the trade name PELLETHANE 2363-75D.This material has a Shore Hardness of about 74 D, a specific gravity ofabout 1.21, a tensile strength of about 165,000 psi, a flexural modulusof about 190,000 psi, an ultimate tensile strength of about 6,980 psiand an ultimate elongation of about 250%. The parison was sealed at oneend while the other end was attached to the source of the pressurizedinflation fluid, in this example nitrogen gas. Clamps were attached toeach end of the parison. The mold was then heated to an operatingtemperature of about 90°-100° C., while the parison was pressurized withnitrogen gas at about 290 psi and held for about 70 seconds.

The pressure was then relieved and the parison was subjected to a seriesof radial expansion or "blow" cycles. During each radial expansion or"blow" cycle, the parison was also axially stretched while beingpressured at about 290 psi for about 5 seconds. The pressure was thenrelieved, and the parison was subject to continued axial stretching forabout 5 seconds. The parison was then subjected to another expansioncycle. After three expansion or blow cycles, the original outer diameterhad increased from 0.035 inches to 0.1181 inches.

The expanded parison was then pressurized to about 190 psi and wassubjected to a heat set step during which the expanded parison was heldfor about 75 seconds at a temperature of about 110° C. The pressurizedballoon was then cooled to about 37° C. for about 30 seconds. Thepressure was then relieved and the balloon was held vertically in themold at about 37° C. for about 120 seconds to minimize ballooncurvature. The balloon was released from the clamps and removed from themold. The balloon, having a nominal or rated diameter of 3.0 mm,displayed an improved overall combination of distensibility, elasticstress response and strength when compared to "compliant" balloons ofthe art and was ready for attachment to a catheter.

EXAMPLE 2

The balloons formed following the process set forth in Example 1 wereplaced in a sterilization chamber and kept at a temperature of about 40°C.±3° C. and a relative humidity of about 55% for about 15 hours. Theballoons are kept at a temperature of about 40° C.±3° C. and were thentreated with 100% ethylene oxide. After being exposed to the ethyleneoxide for about 6 hours, the balloons were removed from thesterilization chamber and held at a temperature of about 40° C.±3° C.and ambient relative humidity for about 22 hours in order to dissipatethe ethylene oxide. At this point, the balloons were sterilized andready for human use.

EXAMPLE 3

The effect which the novel sterilization process of this invention hason the balloons formed using the balloon forming process contemplated bythis invention are demonstrated below. Balloons with a nominal diameterof 3.0 mm were formed from polyurethane following the process describedin Example 1. One group of balloons was subjected to the sterilizationprocess contemplated by this invention and described previously inExample 2, sterilization process contemplated by this invention anddescribed previously in Example 2, while the other group of balloonswere subjected to a sterilization process currently used in the art.

In that sterilization process (referred to in this Example as"traditional sterilization process"), the balloons were preconditionedat a temperature of about 43° C. and a relative humidity of about 60%for about 24 hours. The balloons were then treated with about 12%ethylene oxide and 88% Freon™ at a temperature of about 54° C. Afterbeing treated with the ethylene oxide mixture for about 9 hours, theballoons are removed from the sterilization chamber and kept at atemperature of about 38° C. for about 22 hours.

The average wall tensile, burst pressure, elastic stress response anddistensibility (i.e., radial expansion) of both sets of balloons werecompared below.

    ______________________________________                                                 Average                                                                         Wall     Average  Average                                                     Tensile  Burst    Elastic                                          Sterilization                                                                            Strength Pressure Stress Average                                   Conditions (psi)    (atm)    Response                                                                             Distensibility                            ______________________________________                                        novel sterilization                                                                      16,297   22.0     3.38   9.4%                                      conditions                                                                    described in                                                                  Example 2                                                                     traditional                                                                              14,497   22.6     10.29* 20.2%                                     sterilization                                                                 process                                                                       ______________________________________                                         *The balloons used to determine elastic stress response for this              comparison with the novel sterilization conditions were treated with 100%     ethylene oxide rather than 12% ethylene oxide and 88% Freon ™. All         other temperature and time conditions were the same.                     

EXAMPLE 4

The following example demonstrates the importance of the heat set step.Three dilatation balloons with a nominal or rated diameter of 3.0 mm,were formed from polyurethane following the process described inExample 1. The average burst pressure, distensibility and wall tensilestrength of balloons formed using different heat set temperatures arecompared. The burst pressure and distensibility were determined at 37°C.

    ______________________________________                                        Heat Set T                                                                             Average                                                              Temperature                                                                            Wall Tensile                                                                             Average Burst                                                                             Average                                       (°C.)                                                                           Strength (psi)                                                                           Pressure (atm)                                                                            Distensibility                                ______________________________________                                        160      14,712     12.8        10.26%                                        132      23,364     20.6        5.81%                                         118      25,346     22.2        5.96%                                         ______________________________________                                    

EXAMPLE 5

The following example demonstrates the improved elastic stress responseor "repeatability" which can be obtained by the balloons and ballooncatheters formed following the process contemplated by this invention.In this example, dilatation balloons with a nominal or rated diameter of3.0 mm were formed from polyurethane following the process described inExample 1. A number of polyurethane balloons were sterilized followingthe process previously described in Example 3 (referred to as"traditional sterilization" in this Example). Another group ofpolyurethane balloons were sterilized using the novel sterilizationprocess contemplated by this invention and previously described inExample 2. The elastic stress response of these polyurethanes balloonswere compared with the elastic stress response of other sterilized 3.0mm balloons known in the art.

    ______________________________________                                                      Average  Average Dia-                                                         Diameter meter at 5  Average                                                  at Initial                                                                             Bars After A                                                                              Elastic                                                  5 Bar    Single Infla-                                                                             Stress                                     Balloon       Inflation                                                                              tion to 10 Bars                                                                           Response                                   ______________________________________                                        Polyurethane  2.96     3.06        3.38                                       (sterilization described                                                      in Example 2)                                                                 Polyurethane  2.72     3.00        10.29                                      (traditional sterilization)                                                   Polyethylene  3.02     3.04        0.66                                       terephthalate                                                                 Cross-linked  2.98     3.11        4.36                                       polyethylene                                                                  Cross-linked  2.93     3.19        8.87                                       polyolefin-ionomer                                                            ______________________________________                                    

EXAMPLE 6

The following example demonstrates the improved overall combination ofdistensibility, elastic stress response and wall tensile strengthobtained by forming balloons by using the process of this invention.Balloons with a nominal or rated diameter of 3.0 mm were formed frompolyurethane following the process described in Example 1. The averageelastic stress response, distensibility and wall tensile strength ofthose polyurethane balloons are compared with properties of other 3.0 mmballoons of the art.

    ______________________________________                                                  Average                                                                       Elastic           Average Wall                                                  Stress   Average    Tensile                                       Balloon     Response Distensibility                                                                           Strength (psi)                                ______________________________________                                        Polyurethane                                                                              3.38     9.4%       16,297                                        Polyethylene                                                                              0.66     3.26%      62,081                                        terephthalate                                                                 Cross-linked                                                                              4.36     9.67%      8,868                                         polyethylene                                                                  Cross-linked                                                                              8.87     14.64%     6,793                                         polyolefin-ionomer                                                            ______________________________________                                    

We claim:
 1. A process of forming a dilatation balloon for a catheter comprising:a. providing a parison comprising a block polymer composition including a block copolymer having regions of (i) hard segments defined by regions of intermolecular chain interaction separated by (ii) soft segments regions in which individual polymer portions of chains have the ability to uncoil, said parison having a predetermined initial outer diameter, a predetermined wall thickness and a predetermined length; b. subjecting said parison to at least one axial stretch step and at least one radial expansion step at temperature T₁ which is below the melting temperature of said block polymer composition to increase the diameter and length of said parison to at least three times the original diameter and at least two times the original length and to decrease the original wall thickness such that an expanded parison is formed having an internal diameter between about 6 and about 8 times an initial internal diameter of said parison and an outside diameter which is equal to or greater than 3 times an initial outside diameter of said parison; c. heating said expanded parison to a temperature T₂ which is above T₁ but below the melting temperature of said block polymer composition; and d. cooling said expanded parison to produce said balloon;wherein the ratio of said hard segments to said soft segments provides said balloon with (a) an elastic stress response not greater than 5.00, (b) a wall tensile strength of at least about 14000 psi and (c) a distensibility of between about 5% and about 20%.
 2. The process according to claim 1 wherein said radial expansion step is conducted while said parison is simultaneously subjected to said axial stretch step.
 3. The process according to claim 1 wherein said axial stretch and radial expansion steps are conducted at temperature T₁ which is greater than the glass transition temperature of said block polymer composition.
 4. A process according to claim 1 wherein said block polymer composition is selected from the group consisting of polyester block copolymers, polyamide block copolymers, polyurethane block copolymers, a mixture of nylon and polyamide block copolymers and a mixture of polyethylene terephthalate and polyester block copolymers.
 5. A process according to claim 1 wherein the balloon formed has a distensibility of about 6 to about 17%, an elastic stress response of about 0.75 to about 4.00 and a wall tensile strength of about 16,000 to about 30,000 psi.
 6. A process according to claim 1 wherein said block copolymer is a polyurethane having a Shore Hardness of about 74 D, a specific gravity of about 1.21, a tensile modulus of about 165,000 psi, a flexural modulus of about 190,000 psi, an ultimate tensile strength of about 6,980 psi and an ultimate elongation of about 250%. 